How did Bigmate Philippines Inc. Achieve 99.99% Quality and Zero Customer Complaints in PCB Production?
Bigmate Philippines Inc. is one of the custom plastic injection molding and SMT PCB assembly services companies that have taken the best features in providing quality, achieving a remarkable quality yield of 99.99% with zero customer complaints. All these are possible because of the collaboration and commitment of the excellent team of SMT PCB assembly. The succeeding case study enumerates strategies and processes Bigmate to attain these milestones by being committed to continuous improvement, comprehensive inspections, and customer satisfaction.
The reality of Zero Customer Complaints
Section 1: Identifying and Addressing
Potential Issues
The Initial Challenge
In the competitive world of PCB production, Bigmate faced the challenge of minimizing defects while maintaining high production volumes. The initial defect rate was above the industry average, leading to customer complaints and rework. The need for a systematic approach to identifying and fixing the potential issues before reaching the customers compelled Bigmate to act.
Identify the Root Cause: Conduct a thorough analysis to identify the root cause(s) of the increased defect rate.
> Implement Corrective Actions: Develop and implement specific corrective actions to address the root cause of defects. These actions may include process modifications and equipment maintenance or upgrades.
> Corrective Action Response Time: Establish a target timeframe for addressing and resolving quality issues. Measure the time it takes to identify and implement corrective actions for defects. Aim for a specific response time, such as resolving defects within 48 hours, and track compliance with this target.
Section 2: The Role of Thorough Inspections and Quality Control
Establish Quality Control Checkpoints
Apart from improving the quality, Bigmate established numerous quality control checks along the line of production. These included material inspections, in-process inspections, and final testing.
Continuous Monitoring and Utilization of P-Chart
Bigmate implemented a system of ongoing defect rate monitoring using the so-called P-chart, a specific kind of control chart utilized in quality control. In such a way, the team can trace the performance of every production batch and reveal all kinds of variations from the expected quality standards. Real-time data from this system helped to accelerate corrective action in ensuring that any defects were identified before the product reached the customer.
Section 3: Establishing a Feedback Loop for Continuous Improvement
Collecting and then analyzing client feedback
In pursuit of zero customer complaints, Bigmate established a strong feedback loop with the clients. Customer feedback was collected for each delivery and carefully analyzed for the areas that needed improvement. This feedback loop did bring a difference in refining the processes to meet expectations set by customers.
Corrective Actions Implementation
Bigmate immediately took corrective actions based on feedback. For instance, there’s a customer who complained about major inconsistencies in the functional problem of the electrical components. The team conducted an immediate re-check for the functioning of electrical components. And analyze why it has not been detected in line or how the functioning checker shows the result we conduct a re-inspection immediately.
This was immediately addressed and some additional training was given to the operators concerned. The promptness of the response helped to avoid any future occurrences and kept up the standard of quality.
Section 4: Achieving 99.99% Quality Yield
Success with about 99.99% quality and zero customer complaints was teamwork; it was a joint effort from the supervisors to the operators. Each of Bigmate’s team members was dedicated to excellence. Training sessions were organized regularly to ensure that all employees were tuned to the company’s quality goals and to imbue them with appropriate acumen in maintaining the set high standards.
Long-term customer relationship
This also led to a long-term relationship with the client of Bigmate. Because of their quality products and good customer service, repeat business allowed Bigmate’s reputation to be further cemented in the industry.
Conclusion:
For Inquires, Contact the Following:
Business Inquiry – Bigmate Philippines Inc.
k-machida@bigmateph.com
ma-arayata@bigmateph.com
m-floro@bigmateph.com
